Download TTX25 Pressurized Cartridge Kit

Racing
TTX25 Pressurized Cartridge Kit
Owner’s Manual
Introduction
Öhlins Racing AB - The Story
It was the 1970’s, a young man named Kenth
Öhlin spent most of his spare time pursuing his
favourite sport: motocross.
Congratulations! You are now the owner of
an Öhlins Front Fork Cartridge Kit. More than
two hundred World Championships and other
major world titles are definitive proof that Öhlins
products offer outstanding performance and
reliability.
A careful observer, Kenth’s attention was continually drawn to one specific detail - motocross bikes
had more engine power than their suspension
could handle. It was not long before Kenth realised that better performance could be achieved
by improved wheel suspension.
Every product has gone through rigorous testing
and engineers have spent thousands of hours,
doing their very best to use every possible experience from our 30 years within the racing sport.
The product that you now have in your possession is pure racing breed that is built to withstand.
Öhlins Racing was established in 1976, and just
two years later the company won its first World
Championship title. Despite being in the business
for 30 years, the search for perfection and new
functions is still the main focus of the company.
By installing this Front Fork Cartridge Kit on your
bike you have made a clear statement… you are
a serious rider with a focus on getting the maximal handling ability and outstanding feedback
from your bike. Along comes the fact that your
Front Fork Cartridge Kit will be a long lasting
friend, delivering the very best of comfort and
performance every time you go for a ride. Go
explore!
1
Safety Precautions
Note!
Safety Symbols
The front fork is a very important part of the
vehicle and will therefore affect the stability.
Read and make sure that you understand
the information in this manual and the
mounting instructions before you use this
product. If you have any questions regarding
installation or maintenance please contact an
Öhlins dealer.
In this manual, mounting instructions and
other technical documents, important information concerning safety is distinguished
by the following symbols:
The Safety Alert Symbol means: Warning!
Your safety is involved.
Öhlins Racing AB can not be held
responsible for any damage to the front fork,
vehicle, other property or injury to persons, if
the instructions for installing and maintenance
are not followed exactly.
Warning!
The Warning Symbol means: Failure to
follow warning instructions can result in
severe or fatal injury to anyone working
with, inspecting or using the front fork, or
to bystanders.
Warning!
This product was developed and designed
exclusively for a specific vehicle model and
should only be installed on the intended
vehicle model in its original condition as
delivered from the vehicle manufacturer.
The Caution Symbol means: Special
precautions must be taken to avoid
damage to the front fork.
After installing this product, take a test ride
at low speed to make sure that your vehicle
has maintained its stability.
The Note Symbol indicates information that
is important regarding procedures.
Caution!
Note!
If the suspension makes an abnormal
noise, or the function is irregular, or if you
notice any leakage from the product, please
stop the vehicle immediately and return the
product to an Öhlins Service Centre.
Note!
When working on this product, always consult
your Vehicle Service Manual.
This Manual should be considered a part
of the product and should therefore
accompany the product throughout its life
cycle.
© Öhlins Racing AB. All rights reserved. Any reprinting
or unauthorized use without the written permission of
Öhlins Racing AB is prohibited.
Printed in Sweden.
2
Contents
Introduction
Safety Precautions
1 - Front Fork Cartridge Kit
2 - Design and Function
3 - Setting up the Front Fork
4 - Adjustments
4.1 - Adjusters
4.2 - Spring
4.3 - Oil Level
4.4 - Fork Leg Position
5 - Change Spring and Check/Change Oil Level
6 - Technical Specifications
7 - Inspection and Maintenance
3
1
2
4
5
9
10
10
11
11
12
14
14
1 - Front Fork Cartridge Kit
Introduction
The product in your hand is an artwork, prepared
by our dedicated craftsmen at our facility in Upplands Väsby, Sweden. Its predecessors have
battled their way on numerous race tracks in
World Superbike, Supersport, Superstock and
AMA and the legacy continues in your front fork.
Thousands of hours have been spent together
with some of the best teams in the world to find
the optimal design and functionality to give you
as much performance and comfort as possible.
You will feel the difference…be sure.
Our engineers that work on a daily basis with the
top riders in the world often hear the word “feeling” and “control” when they debrief after tests
and races.
We wanted to pour as much of these
important factors into your front fork cartridge
kit and, as a result, the new TTX25 front fork
cartridge kit gives you improved “brake support”
and “tire feel” when riding. For all of you that
have your mind set on doing some serious
racing we have some really good news.
Of course we have improved the design so
that you easily can have it properly maintained
and every kit is individually tested with an
optimum setting, spring and top-out spring.
The new top-cap design will send a signal to
all curious spectators when you pull over next
to your favourite café or local race track… it’s a
signal that says that the owner of the bike has
made his choice to go straight for the podium.
Now we are raising the new TTX25 front fork
cartridge kit to a new level.
Design
The DNA of this new TTX25 front fork cartridge
kit originates in the most prestigious race series
in the world and the front fork cartridge kit is
weight optimized as a result of that fact. We have
used exclusive racing components from our R&D
department to increase the performance of the
front fork cartridge kit.
4
2 - Design and Function
The front fork cartridge kit is divided into one
compression cartridge and one rebound cartridge. The compression cartridge is installed in
the left front fork leg and the rebound cartridge in
the right front fork leg. Marked at the top cap is
“COMP” for compression adjustment and “REB”
for rebound adjustment (Fig. 1).
The compression and rebound cartridges are
both of the same design but works opposite
each other. To achieve rebound damping
force instead of compression damping force,
the cylinder tubes and the pistons are turned
opposite each other between the compression
and the rebound cartridges (Fig. 2).
When the front fork moves, the fluid inside
is forced to flow through the pistons. At a
compression movement the fluid is forced
through the compression shim stack and at the
same time through the rebound check valve.
And opposite, at a rebound movement the fluid
is forced through the rebound shim stack and
through the compression check valve.
The fluid displaced by the shafts are directed
to a reservoir in the bottom of the cartridges. In
the reservoir a dividing piston pressurizes the oil
with 6 Bars of gas. (Fig. 2)
The compression and the rebound pistons are
both of the same design. The pistons have three
flow paths for the fluid:
1. Bleed valve (Fig. 3 centre gray arrows).
Small orifice that creates a flow restriction
simply by being small.
2. Shim valve (Fig. 3 outer black arrows). Fluid
pressure has to deflect thin steel washers
(shims) to open up an orifice and allow fluid
to flow through it.
3. Check valve (Fig. 3 outer white arrows). A
spring preloaded shim that opens easily,
for return flow of fluid when the direction of
movement of the front fork changes.
The bleed valve and shim valve build up damping force. At slow stroke speeds the percentage
going through the bleed valve is higher and at
fast strokes the shim valve takes care of most of
the flow.
The check valve, together with the bleed
valve (since it can flow both directions), handle
return flows.
To control damping force the bleed valve
can be changed by the external adjuster,
compression and rebound.
By altering the stiffness of the shim stack
(number, thickness, diameter and shape) on the
shim valve the characteristics of the damping
action can be changed. This should only be
done by an authorized Öhlins service workshop.
Fig. 1 - Cartridges
Top cap
marked
“REB”
Rebound Cartridge
Compression Cartridge
Top cap
marked
“COMP”
5
2 - Design and Function
Fig. 2 - Schematic View
Compression
Front Fork Leg
Rebound
Front Fork Leg
Cylinder tube
holes
A
A-A
Oil flow
Compression
shims stack
Check valve
shims stack
Piston
Piston
Check valve
shims stack
Rebound
shims stack
Oil
Outer tube
Cylinder tube
Cylinder tube holes
A
Dividing wall
Oil
Dividing piston
Gas 6 bar
Dividing wall
Cylinder tube
Fig. 3 - Piston Oil Flow
Compression
Rebound
Bleed valve flow
Bleed valve flow
Compression
shims stack
Piston
Check valve
shims stack
Check valve flow
Shim valve flow
Piston
Check valve flow
Shim valve flow
Check valve
shims stack
Rebound
shims stack
6
2 - Design and Function
Compression damping
Rebound damping
Compression front fork leg
When movement of the motorcycle causes compression of the front fork (Fig. 4 compression
movement), the fluid below the compression piston is pressurized and goes through:
• Compression shims stack
• Compression bleed valve
Rebound front fork leg
When the spring forces the front fork to extend again (Fig. 5 rebound movement), the fluid
above the rebound piston is pressurized and in a
similar pattern as compression movement, goes
through:
• Rebound shims stack
• Rebound bleed valve
Rebound front fork leg
The gas pressure behind the dividing piston
causes the fluid to go through:
• Rebound check valve shims stack
• Rebound bleed valve (Small and insignificant
flow compared to the check valve)
Compression front fork leg
Similar to rebound front fork leg at compression
damping, the gas pressure behind the dividing
piston causes the fluid to go through:
• Compression check valve shims stack
• Compression bleed valve (Small and insignificant flow compared to the check valve)
Displaced fluid
During compression movement, the shaft enters
the cylinder tube and the correspondingly displaced volume of fluid has to flow out of the cylinder tube through the holes. The fluid flows out
from the holes in the cylinder tube, between the
cylinder tube and the outer cylinder tube down
through the dividing wall to the reservoir in the
bottom of the cartridge. In the reservoir a dividing
piston pressurizes the oil with 6 Bars of gas. The
dividing piston moves by the displaced fluid.
Displaced fluid
The fluid that was displaced by the piston shaft is
now pushed back from the reservoir into the cylinder tube by the dividing piston movement.
7
2 - Design and Function
Fig. 4 - Front Fork Oil Flow Compression Movement
Compression
Front Fork Leg
Fig. 5 - Front Fork Oil Flow Rebound Movement
Rebound
Front Fork Leg
Compression
Front Fork Leg
Cylinder
tube
holes
Check
valve
Shims
stack
Piston
Check
valve
Dividing
piston
movement
Cylinder
tube
holes
Piston
Shims
stack
Oil
Gas
8
Rebound
Front Fork Leg
3 - Setting up the Front Fork
Recommended Measures
If no other recommendations are given in the
Mounting Instructions follow the measures below:
Warning!
Before riding, always ensure that the basic
settings made by Öhlins are intact. Take
notes, adjust in small steps and make only one
adjustment at a time.
Free sag/ Without Rider (R1-R2), (F1-F2)
Rear
5 - 15 mm
Front
20 - 30 mm
Step 1
Ride height/ With Rider (R1-R3), (F1-F3)
Rear
25 - 35 mm
Front
30 - 40 mm
Spring Preload - Free Sag - Ride Height
Spring preload is a crucial part of setting your
motorcycle since it affects the height of the motorcycle and the fork angle. Before setting the
preload, measure the sag:
Note!
Always check on the Öhlins web site www.ohlins.com or with your Öhlins dealer/ distributor for the latest information.
Note!
The following procedure should be performed on
a flat surface.
Step 2
Adjust spring preload
1. If your measures differ significantly from the
recommendations in the Mounting Instructions
or the table above, adjust the spring preload.
(See chapter Spring Preload in this manual).
2. If the ride height still differs from the recommendations, you may need to change to softer/harder spring. Contact your Öhlins dealer
for advise.
1. Put the motorcycle on a workstand so that
both wheels are off the ground and the suspension is unloaded.
2. Mark, for example with a piece of tape, a point
immediately above the rear wheel axle.
3. Measure the distance from the marked
point to a fixed point, for example the wheel
axle (R1).
4. Measure the distance from the bottom of the
upper triple clamp to a fixed point, for example
the front wheel axle (F1).
5. Put the motorcycle on the ground so that the
front and the rear suspensions are slightly
compressed. Repeat the measuring procedures (R2 and F2).
6. Sit on the motorcycle in normal riding position,
properly outfitted in your riding gear. Repeat
the measuring procedure (R3 and F3).
Warning!
Incorrect spring rate may result in a front
geometry that is either too steep or too flat.
This can result in a tendency of under or over
steering, that could seriously affect the handling
characteristics of the motorcycle.
9
4 - Adjustments
4.1 - Adjusters
• Spring preload adjuster Use a 14 mm wrench to turn the upper adjustment screw. Maximum adjustment range is 18
mm. One turn of the adjustment screw will cause
1 mm change in spring preload.
Spring preload adjuster
• Compression damping adjuster
Left front fork leg.
• Rebound damping adjuster
Right front fork leg.
Adjust Compression and Rebound;
Use a 3 mm allen key. Adjustment range from
fully closed valve (clockwise) to fully open valve
(counter-clockwise) is about 20 “clicks”. Recommended “clicks” from closed position according
to your mounting instruction for your Front Fork
Cartridge Kit.
Compression adjuster
4.2 - Spring
The spring recommended in the Mounting Instructions is chosen after evaluations performed
on a test track according to motorcycle characteristics for your specific motorcycle model. Due
to variations in ride style, track conditions, body
shape etc. the spring is often a subject for additional fine‑tuning.
Springs are available in 0.5 N/mm intervals
from 6.5 N/mm to 11.5 N/mm but the rate can
be set to 0.25 N/mm increments by using two
different rates. A method used on the race track.
Rebound adjuster
Example:
Using 9.5 N/mm in the right front fork leg
and 10.0 N in the left front fork leg gives a combined spring rate of 9.75 N/mm.
10
4 - Adjustments
4.3 - Oil Level
Compared to conventional type of front forks, the
upside down front forks are very sensitive to variations in oil level. Therefore, adjust the oil level
with special care. A change in the front fork oil
level will not affect the air spring force in the early
stage of the movement, but will have a greater effect in the later stage.
Öhlins Front Fork Fluid
When the oil level is raised:
The air spring in the later half stage of travel is
stronger, and thus the front fork harder.
The upper edge of the outer
front fork leg
When the oil level is lowered:
The air spring in the later half stage of travel is
lessened, and thus the front fork is softer.
Oil level
Note!
When measuring oil level; remove spring and
preload tube, make sure the shaft assembly is in
the bottom of the fork leg and that the outer tube
is in its bottom position. Measure the oil level
with a ruler. See set-up data and oil level-force
diagram in this folder.
Oil level diagram
The Diagram shows several curves for the force
that equals to a specific oil level. For recommended oil level, see the Mounting Instructions.
If the Mounting Instructions was not included
in your Front Fork Cartridge Kit, please contact an Öhlins dealer.
4.4 - Fork Leg Position
The Fork Leg Position changes the ride height
at the front. To measure the Fork Leg Position;
measure the distance between the outer tube
and the upper triple clamp. For recommended
Fork Leg Position, see the Mounting Instructions.
Fork leg position
11
5 - Change Spring and Check/Change Oil Level
Warning!
This procedure requires high technical knowledge
and/or experience of working with front forks. If
you feel any insecurity regarding this procedure,
contact an Öhlins dealer for advice. See the
Vehicle Service Manual.
1
Note!
The following procedure is performed on front
fork legs installed in the vehicle.
2
1
Release the spring preload fully (counter clockwise).
3
2
Loosen the upper triple clamp by loosening the
screws.
3
Loosen the top cap from the outer tube, use tool
00797-08.
4
Remove the top cap from the shaft extension.
Use a 19 and a 14 mm wrench to loosen the top
cap.
4
5
Remove the spring support, the spring and the
preload tube. Check the oil level, see figure.
Check/Change Oil Level
Note!
We recommend you to check the oil level
since spring removal affects the oil level.
Measure oil level without spring or preload
tube according to chapter “Setting Up - Oil
Level”.
XXX mm
12
5 - Change Spring and Check/Change Oil Level
6
Put the preload tube and the spring on top of
the cartridge. See available springs in chapter
Technical Specifications.
The marking
facing up.
6
7
Fasten tool 01765-03 on the top of the shaft extension. Install the spring support by leading it
over the tool.
7
Tool
1765-03
8
Pull up the shaft assembly and grab the spring
support with a 19 mm wrench.
Spring
support
Preload
tube
9
Open the compression and rebound adjusters
fully. Remove the pull-up tool and install the top
cap to the shaft extension. Torque: 15 Nm.
10
Make sure the front fork leg is in a fully extended
position. Use tool 00797‑08 to tighten the top cap
to the outer tube.
Torque 10 Nm.
8
11
Set the spring preload, rebound and compression
adjusters according to adjustments and set-up
data in the Mounting Instructions.
Spring
support
19 mm
wrench
12
Tighten the upper triple clamp with 20 Nm.
9
10
13
6 - Technical Specifications
Front Fork length
See specification card for your specific Front Fork
Cartridge Kit.
Available Springs:
Part No.
08790-65
08790-70
08790-75
08790-80 08790-85 08790-90 08790-95 08790-10 08790-05 08790-11 08790-15
Stroke
See specification card for your specific Front Fork
Cartridge Kit.
Free spring length
260 mm
Compression adjustment
Maximum open valve about 20 clicks.
Rebound adjustment
Maximum open valve about 20 clicks.
Spring Rate
6.5 N/mm
7.0 N/mm
7.5 N/mm
8.0 N/mm
8.5 N/mm
9.0 N/mm
9.5 N/mm
10.0 N/mm
10.5 N/mm
11.0 N/mm
11.5 N/mm
Oil Level
See specification card or Mounting Instructions
for your specific Front Fork Cartridge Kit.
Spring preload adjustment
0 - 18 mm (0 - 18 turns)
Spring rate
Please see specification card or Mounting
Instructions for your specific Front Fork Cartridge Kit.
Caution!
Use only Öhlins high performance Front Fork
Fluid  (01309-01).
7 - Inspection and Maintenance
Note!
Preventive maintenance and regular inspection
reduces the risk of functional disturbance. If there
is any need for additional service, please contact
an authorised Öhlins service workshop.
Discarded Öhlins products should be handed
over to an authorized work shop or distributor for
proper disposal.
Service Intervals
This product is designed for racing use only.
Recommended Service and Maintenance every 10 hrs
14
Owner’s Manual 25mm Pressurized Cartridge Kit | Part No 07286-01_0 | Issued 2011-01-20 | © 2011 Öhlins Racing AB
Your Öhlins retailer:
Öhlins Racing AB
Box 722
SE-194 27, Upplands Väsby
Sweden
Phone: +46 (0)8 590 025 00
Fax: +46 (0)8 590 025 80
www.ohlins.com